U.S. patent application number 15/833998 was filed with the patent office on 2018-04-12 for wear part monitoring.
The applicant listed for this patent is ESCO Corporation. Invention is credited to ERIC L. BEWLEY, JOSEPH E. BLOMBERG, NOAH D. COWGILL.
Application Number | 20180100291 15/833998 |
Document ID | / |
Family ID | 53180280 |
Filed Date | 2018-04-12 |
United States Patent
Application |
20180100291 |
Kind Code |
A1 |
BEWLEY; ERIC L. ; et
al. |
April 12, 2018 |
WEAR PART MONITORING
Abstract
A process and tool for monitoring the status, health, and
performance of wear parts used on earth working equipment. The
process and tool allow the operator to optimize the performance of
the earth working equipment. The tool has a clear line of site to
the wear parts during use and may be integrated with a bucket or
blade on the earth working equipment.
Inventors: |
BEWLEY; ERIC L.; (Salem,
OR) ; COWGILL; NOAH D.; (Portland, OR) ;
BLOMBERG; JOSEPH E.; (Portland, OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ESCO Corporation |
Portland |
OR |
US |
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|
Family ID: |
53180280 |
Appl. No.: |
15/833998 |
Filed: |
December 6, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15588453 |
May 5, 2017 |
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15833998 |
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14548278 |
Nov 19, 2014 |
9670649 |
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15588453 |
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61908458 |
Nov 25, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G06K 9/4604 20130101;
A01B 15/00 20130101; E02F 9/267 20130101; E02F 9/2816 20130101;
E02F 9/2808 20130101; A01B 23/02 20130101; G07C 5/0808 20130101;
E02F 3/815 20130101; E02F 9/2833 20130101; G07C 5/006 20130101;
E02F 9/24 20130101; A01B 15/06 20130101; E02F 9/2883 20130101 |
International
Class: |
E02F 9/26 20060101
E02F009/26; G07C 5/00 20060101 G07C005/00; E02F 9/28 20060101
E02F009/28; G07C 5/08 20060101 G07C005/08 |
Claims
1-47. (canceled)
48. A system for monitoring earth working equipment, the system
comprising: at least one electronic sensor detecting at least one
characteristic of an earth working operation in each of a plurality
of operational cycles, and wirelessly transmitting such
information; a programmable logic device using the transmitted
information to make an assessment regarding the operation; and a
human machine interface providing the assessment to an operator of
the earth working equipment during use to allow the operator to
adjust the use of the earth working equipment on account of the
assessment.
49. The system of claim 48 wherein the at least one detected
characteristic includes an amount of earthen material gathered in a
bucket secured to the earth working equipment, and the operational
cycle is a digging cycle.
50. The system of claim 49 wherein the assessment includes a
percentage of the bucket that is filled during each digging
cycle.
51. The system of claim 49 wherein the assessment includes a volume
of earthen material gathered in the bucket during each digging
cycle.
52. The system of claim 49 wherein the assessment can be used to
adjust the digging to optimally fill the bucket.
53. The system of claim 49 wherein the at least one detected
characteristic includes a duration of each of the digging
cycles.
54. The system of claim 49 including a database storing fill
profiles for the bucket, wherein the at least one electronic sensor
detects a distance between the at least one electronic sensor and
the earthen material in the bucket along a line of sight, and the
programmable logic device uses the distance and the fill profiles
to make the assessment.
55. The system of claim 54 wherein the database stores the
transmitted information for each of the digging cycles, and the
programmable logic device uses the transmitted information from a
current digging cycle and past digging cycles to make the
assessment.
56. The system of claim 49 including a database to store the
transmitted information for each of the digging cycles, wherein the
programmable logic device uses the transmitted information from a
current digging cycle and past digging cycles to make the
assessment.
57. The system of claim 49 wherein the at least one detected
characteristic includes a duration of each of the digging
cycles.
58. The system of claim 48 wherein the at least one detected
characteristic includes an amount of earthen material gathered in a
truck tray by the earth working equipment, and the operational
cycle is one filling of the truck tray.
59. The system of claim 58 wherein the at least one detected
characteristic includes an amount of earthen material gathered in a
bucket secured to the earth working equipment during each digging
cycle.
60. The system of claim 59 wherein the assessment can be used to
adjust the digging to optimally fill the truck tray.
61. The system of claim 60 wherein the at least one electronic
sensor includes a first electronic sensor secured to the bucket and
a second electronic sensor secured to the truck tray.
62. The system of claim 58 wherein the assessment can be used to
adjust the digging to optimally fill the truck tray.
63. The system of claim 58 wherein the at least one electronic
sensor is secured to the truck tray.
64. The system of claim 58 including a database storing fill
profiles for the truck tray, wherein the at least one electronic
sensor detects a distance between the at least one electronic
sensor and the earthen material in the truck tray along a line of
sight, and the programmable logic device uses the distance and the
fill profiles to make the assessment.
65. The system of claim 64 wherein the database stores the
transmitted information for each of the operational cycles, and the
programmable logic device uses the transmitted information from a
current operational cycle and past operational cycles to make the
assessment.
66. The system of claim 58 including a database to store the
transmitted information for each of the operational cycles, wherein
the programmable logic device uses the transmitted information from
a current operational cycle and past operational cycles to make the
assessment.
67. The system of claim 48 wherein the earth working equipment
includes a bucket, the operational cycle is a digging cycle, and
the at least one detected characteristic includes the duration of
the digging cycle.
68. A system for monitoring earth working equipment, the system
comprising: at least one electronic sensor detecting at least one
characteristic of an earth working operation in each of a plurality
of operational cycles, and wirelessly transmitting such
information; a database to store the transmitted information for
each of the operational cycles; and a programmable logic device
using the transmitted information from a current operational cycle
and past operational cycles to make an assessment regarding the
operation.
69. The system of claim 68 including a human machine interface
making the assessment accessible to an operator of the earth
working machine to allow the operator to adjust the operation on
account of the assessment.
70. The system of claim 68 wherein the at least one detected
characteristic includes an amount of earthen material gathered in a
bucket secured to the earth working equipment, and the operational
cycle is a digging cycle.
71. The system of claim 70 wherein the at least one detected
characteristic includes a duration of each of the digging
cycles.
72. The system of claim 70 including a database storing fill
profiles for the bucket, wherein the at least one electronic sensor
detects a distance between the at least one electronic sensor and
the earthen material in the bucket along a line of sight, and the
programmable logic device uses the distance and the fill profiles
to make the assessment.
73. The system of claim 70 wherein the at least one detected
characteristic includes a duration of each of the digging
cycles.
74. The system of claim 68 wherein the at least one detected
characteristic includes an amount of earthen material gathered in a
truck tray by the earth working equipment, and the operational
cycle is one filling of the truck tray.
75. The system of claim 74 wherein the at least one detected
characteristic includes an amount of earthen material gathered in a
bucket secured to the earth working equipment during each digging
cycle.
76. The system of claim 75 wherein the assessment can be used to
adjust the digging to optimally fill the truck tray.
77. The system of claim 76 wherein the at least one electronic
sensor includes a first electronic sensor secured to the bucket and
a second electronic sensor secured to the truck tray.
78. The system of claim 74 wherein the assessment can be used to
adjust the operation to optimally fill the truck tray.
79. The system of claim 74 wherein the at least one electronic
sensor is secured to the truck tray.
80. The system of claim 74 wherein the at least one characteristic
includes a duration of the operational cycle.
81. A system for monitoring earth working equipment, the system
comprising: a first electronic sensor detecting an amount of
earthen material gathered in a bucket secured to the earth working
equipment during each of a plurality of digging cycles, and
wirelessly transmitting such information; a second electronic
sensor detecting the amount of earthen material in a truck tray
loaded by the bucket, and wirelessly transmitting such information;
and a programmable logic device using the transmitted information
from the first and second electronic sensors to determine a fill of
the bucket in each digging cycle to optimally fill the truck
tray.
82. The system of claim 81 including a human machine interface
making the determination by the programmable logic device
accessible to an operator of the earth working machine to allow the
operator to adjust the digging on account of the determination.
83. The system of claim 82 including a database storing fill
profiles for the bucket, wherein the first electronic sensor
detects a distance between the at least one electronic sensor and
the earthen material in the bucket along a line of sight, and the
programmable logic device uses the distance and the fill profiles
to make an assessment of the amount of earthen material in the
bucket during each digging cycle.
84. The system of claim 83 including a database to store the
transmitted information for each of the digging cycles, and the
programmable logic device uses the transmitted information from a
current digging cycle and past digging cycles to make the
assessment, which is related to performance of the digging.
85. The system of claim 81 including a database to store the
transmitted information for each of the digging cycles, and the
programmable logic device uses the transmitted information from a
current digging cycle and past digging cycles to make the
assessment.
86. The system of claim 81 wherein the first electronic sensor
detects a duration of each digging cycle, and the programmable
logic device uses the duration to make the determination.
87. A system for monitoring earth working equipment, the system
comprising: at least one electronic sensor detecting an amount of
earthen material gathered in a truck tray by earth working
equipment and a characteristic of an operational cycle of the
operation, and wirelessly transmitting such information; and a
programmable logic device using the transmitted information to make
an assessment regarding the operation.
88. The system of claim 87 wherein the operational cycle includes
the filling of the truck tray, and the characteristic includes a
count of digging cycles of the earthen material to complete one
operational cycle.
89. The system of claim 88 wherein the characteristic includes a
duration of the operational cycle.
90. The system of claim 87 wherein the operational cycle is the
filling of the truck tray, and the characteristic includes a
duration of the operational cycle.
91. The system of claim 87 including a human machine interface
making the assessment accessible to an operator of the earth
working machine to allow the operator to adjust the operation on
account of the determination.
92. The system of claim 87 including a database to store the
transmitted information for each of the operational cycles, and the
programmable logic device uses the transmitted information from a
current operational cycle and past operational cycles to make the
assessment.
93. A system for monitoring earth working equipment, the system
comprising: at least one electronic sensor detecting (i) an amount
of earthen material in a truck tray being filled by the earth
working equipment with a bucket, and (ii) a number of digging
cycles of the earth working equipment used to fill the truck tray;
and a programmable logic device using information detected by the
at least one electronic sensor to make an assessment related to the
filling of the truck tray.
94. The system of claim 93 including a human machine interface
making the assessment by the programmable logic device accessible
to an operator of the earth working machine to allow the operator
to adjust the digging on account of the assessment.
95. The system of claim 93 wherein the at least one electronic
sensor detects a duration of each digging cycle.
96. The system of claim 93 wherein the at least one electronic
sensor includes a first electronic sensor secured to the bucket and
a second electronic sensor secured to the truck tray.
97. A system for monitoring earth working equipment comprising: a
bucket secured to the earth working equipment; at least one
electronic sensor to detect earthen material in the bucket during
use, and wirelessly transmitting such information; and a
programmable logic device using the transmitted information to
determine the amount of earthen material in the bucket.
98. The system of claim 97 including a human machine interface
making the assessment by the programmable logic device accessible
to an operator of the earth working machine to allow the operator
to adjust the digging on account of the assessment.
99. The system of claim 97 including a database storing fill
profiles for the bucket, wherein the at least one electronic sensor
detects a level of the earthen material in the bucket along a line
of sight, and the programmable logic device uses the detected level
and the fill profiles to determine the amount of earthen material
in the bucket.
100. The system of claim 99 wherein the at least one electronic
sensor is secured to the bucket.
101. A system for monitoring earth working equipment comprising: a
ground engaging product including a base secured to the earth
working equipment and a wear part secured to the base, and operated
in a cycle by the earth working equipment; and at least one
electronic sensor secured to the ground engaging product to detect
the beginning of each cycle and wirelessly transmitting such
information.
102. The system of claim 101 including a programmable logic device
using the transmitted information to make an assessment of the
earth working operation.
103. The system of claim 102 including a human machine interface
making the assessment by the programmable logic device accessible
to an operator of the earth working machine to allow the operator
to adjust the operation on account of the assessment.
Description
RELATED APPLICATION
[0001] This application claims priority benefits to U.S.
Provisional Patent Application No. 61/908458 filed Nov. 25, 2013
and entitled "Wear Part Monitoring," which is incorporated herein
by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention pertains to a system and tool for
monitoring the status, health, and performance of wear parts used
on various kinds of earth working equipment.
BACKGROUND OF THE INVENTION
[0003] In mining and construction, wear parts (e.g., teeth,
shrouds, and lips) are commonly provided along the edges of
excavating equipment to protect the underlying equipment from undue
wear and, in some cases, also perform other functions such as
breaking up the ground ahead of the digging edge. For example,
buckets for dragline machines, cable shovels, face shovels,
hydraulic excavators, and the like are typically provided with
multiple wear components such as excavating teeth and shrouds that
are attached to a lip of a bucket. A tooth typically includes an
adapter secured to the lip of a bucket and a wear member attached
to the adapter to initiate contact with the ground and break up the
ground ahead of the digging edge of the bucket.
[0004] During use, the wear parts typically encounter heavy loading
and highly abrasive conditions that at times cause the wear parts
to become disengaged and lost from the excavating machine. For
example, as a bucket engages the ground a wear member, also known
as a point, occasionally will be lost from the adapter. The
operators of the excavating machines are not always able to see
when a wear part has been lost. It is well known that a lost wear
part may cause damage to downstream excavating equipment. For
example, a lost wear member may cause damage that leads to
additional downtime for conveyors, screens, pumps, and crushers. If
a wear part becomes caught in a crusher, the wear part may be
ejected and cause a hazard to workers or it may be jammed and
require an operator to dislodge the part, which at times may be a
difficult, time-consuming and/or hazardous process. Additionally,
continuing to operate the excavating equipment with missing wear
parts can lead to a decrease in production and excessive wear on
other components on the excavating equipment.
[0005] The abrasive environment causes the wear parts to eventually
become worn. If the wear parts are not replaced at the appropriate
time, an excessively worn wear part can be lost, production may
decrease, and other components of the excavating equipment may
experience unnecessary wear.
[0006] Systems with varying degrees of success have been used to
monitor when a wear member has been worn or damaged and needs
replacement. For example, the Tooth-Wear Monitoring system and
Missing Tooth Detection system sold by Motion Metrics uses an
optical camera mounted on a shovel boom of excavating equipment. In
addition, U.S. Pat. No. 8,411,930 relates to a system and method
for detecting damaged or missing wear members. The system has a
vibration resistant video camera that is preferably mounted on a
shovel boom. Because the above systems are located on the shovel
boom, the systems only have a clear view of the wear members during
a portion of the digging and dumping operation. As a result, there
is potential for the systems to not immediately register that a
wear member has been lost or needs replacement. In addition should
the systems incorrectly register that a wear member has been lost,
the systems may have to wait until the next digging and dumping
cycle to confirm that the wear member is truly lost and that an
object was not obstructing the systems view and registering a false
alarm.
[0007] Other systems with varying degrees of success have been used
to monitor if a wear member is secured to the base on an excavating
machine. For example, mechanical systems have been fixed between
the wear member and the base for detecting the absence and presence
of the wear member. In U.S. Pat. No. 6,870,485, the system contains
a spring loaded switch between the wear parts. When the wear parts
are separated an electrical switch activates a radio transmitter
alerting the operator that a wear part has been lost. In U.S. Pat.
No. 5,743,031, the system comprises an indicator attached to the
tooth and an actuator secured to the nose. In one example, the
actuator actuates, a smoke canister to provide a visual signal that
the tooth has fallen off or is about to fall off. These systems do
not determine when a wear member has reached the end of life and
needs to be replaced and these mechanical systems can be costly and
cumbersome to install when a wear member is worn and needs
replacement.
SUMMARY OF THE INVENTION
[0008] The present invention pertains to a system and tool for
monitoring wear parts for earth working equipment. The monitoring
tool is particularly well suited for monitoring the presence and
health (i.e., the current wear profile) of wear parts utilized with
buckets used for excavating in mining and construction
environments.
[0009] In one aspect of the invention, electronic sensors are used
in conjunction with programmable logic to determine if wear parts
are present on the earth working equipment. If a wear part is not
present the programmable logic triggers an alert. The alert
notifies the operator when a wear part has been lost from the
excavating equipment. This allows the operator to take the
necessary actions to ensure that the missing wear part is replaced
and that the missing wear part does not damage downstream
excavating equipment. As examples, the electronic sensor may be a
camera, a laser range finder, an ultrasonic sensor, or another
distance measuring sensor. In one preferred construction, the
camera is chosen from a group consisting of 2D cameras, 3D cameras,
and infrared cameras.
[0010] In another aspect of the invention, electronic sensors are
used in conjunction with programmable logic to determine the degree
a wear part on the earth working equipment has been worn. If the
wear part is worn a predetermined amount the programmable logic
triggers an alert. The alert notifies the operator when a worn wear
part should be replaced. This allows the operator to take the
actions needed to replace the worn wear part so that other
components of the earth working equipment do not experience
unnecessary wear. As examples, the electronic sensor may be a
camera, a laser range finder, an ultrasonic sensor, or another
distance measuring sensor. In one preferred construction, the
camera is chosen from a group consisting of 2D cameras, 3D cameras,
and infrared cameras.
[0011] In another aspect of the invention, electronic sensors are
used in conjunction with programmable logic to determine how full a
bucket is loaded during a digging operation. In one preferred
construction, the programmable logic may be programed to
communicate the current and past loads for each digging cycle to an
operator or wireless device. This allows the operator to adjust the
digging operation to optimally fill the bucket to the desired
capacity. This system could be a stand-alone system or integrated
with another system such as a monitoring system for monitoring the
presence and/or health of wear parts installed on the bucket. As
examples, the electronic sensor may be a camera, a laser range
finder, an ultrasonic sensor, or another distance measuring sensor.
In one preferred construction, the camera is chosen from a group
consisting of 2D cameras, 3D cameras, and infrared cameras.
[0012] In another aspect of the invention, electronic sensors and
programmable logic are used to determine a percentage that the
bucket has been filled. The percentage may be determined by
measuring the current fill of the bucket and comparing the current
fill to the rated capacity of the bucket. The electronic sensor may
be, for example, a camera, a laser range finder, an ultrasonic
sensor, or another distance measuring sensor. In one preferred
construction, the camera is chosen from a group consisting of 2D
cameras, 3D cameras, and infrared cameras. This system could be a
stand-alone system or integrated with another system such as a
bucket fill monitoring system.
[0013] In another aspect of the invention, electronic sensors are
used to determine the digging cycle time. In one preferred
construction, programmable logic may be programed to communicate
the current cycle time and past cycle times for each digging cycle
of the bucket to an operator or wireless device. This allows the
operator to adjust the digging operation for optimal performance.
As examples, an accelerometer and/or an inclinometer may be used to
determine the beginning of a digging cycle. This system may be a
stand-alone system or may be integrated with another system such as
a monitoring system for monitoring the presence and/or health of
wear parts installed on the bucket.
[0014] In another aspect of the invention, electronic sensors are
used to determine high impact events on a bucket digging edge
(i.e., higher than experienced during the normal digging
operation). In one preferred construction, programmable logic may
record the time of the high impact event. The programmable logic
may be programed to communicate the high impact events to an
operator or wireless device. As an example, an accelerometer may be
used to determine when a high impact event occurs. This system may
be a stand-alone system but can be integrated with another system
such as a monitoring system for monitoring the presence and/or
health of wear parts installed on the bucket. This allows an
operator or maintenance personnel to better determine what may have
caused the current state of the wear parts (e.g., the wear member
is present, the wear member is lost, and the wear member is
worn).
[0015] In another aspect of the invention, a tool is installed on a
wear part that engages and moves the earth to be excavated. In one
preferred construction the tool is installed on a bucket used for
excavating so that the monitoring system has a clear line of sight
to a digging edge of the bucket throughout the digging and dumping
operation. The tool may be secured to an interior surface of the
bucket or the tool may be secured to an exterior surface of the
bucket. As examples, the monitoring system may be integrated with
the shell of the bucket, integrated between two interior plates of
a bucket having a double wall shell, or installed on the bridge or
top of the bucket.
[0016] In another aspect of the invention, features are
incorporated onto the wear part to aid in absence and presence
detection. In one preferred construction, the features are
incorporated onto an adapter so that if the monitoring system is
able to detect the feature the monitoring system is programmed to
send an alert that the wear member has been lost. In another
preferred construction, the features are incorporated onto the wear
member so that if the monitoring system is able to detect the
feature the monitoring system is programmed to indicate that the
wear member has not been lost from the excavating equipment.
[0017] In another aspect of the invention, features are
incorporated onto the wear part to aid in determining the degree a
wear part on the excavating equipment has been worn. In one
preferred construction, a wear part contains multiple features
along the length of the expected wear profile so that as the wear
part wears the monitoring system is able to detect the number of
features remaining on the wear part.
[0018] In another aspect of the invention, the monitoring system
provides alerts to equipment operators, databases, and remote
devises when the wear parts on the excavating equipment need
maintenance. In one preferred construction, the monitoring system
communicates wirelessly.
[0019] In another aspect of the invention, the monitoring system is
provided with a device to display or indicate the status, health,
and performance of the wear parts. In one preferred construction,
the monitoring system is provided with a monitor. In another
preferred construction, the monitoring system is integrated with a
display system that is a part of the excavating equipment being
monitored or a display that is remote to the monitoring system.
[0020] In another aspect of the invention, the monitoring system
stores the history of the status, health, and performance of the
wear parts.
[0021] In another aspect of the invention, the monitoring system
utilizes lights to illuminate the wear parts to be monitored so
that the electronic sensors provide accurate readings regarding the
status, health, and performance of the wear parts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a side view of a prior art mining excavator.
[0023] FIG. 2 is a perspective view of a prior art excavator hoe
bucket.
[0024] FIG. 3 is a perspective view of a prior art lip of an
excavator hoe bucket.
[0025] FIG. 4 is a perspective view of a prior art tooth
assembly.
[0026] FIG. 5 is an exploded perspective view of the tooth assembly
shown in FIG. 4.
[0027] FIG. 6 is a partially exploded perspective view of a prior
art tooth assembly only having a point and an adapter.
[0028] FIG. 7A and 7B outline the general process steps for
monitoring the status and health of wear parts in accordance with
the present invention.
[0029] FIG. 8 is a cross section of a monitoring system of the
present invention.
[0030] FIG. 9 is a perspective view of a bucket with a monitoring
system installed on the bridge of the bucket in accordance with the
present invention.
[0031] FIG. 10 is a perspective view of a top portion of a
hydraulic face shovel bucket with a monitoring system integrated
with the shell of the bucket in accordance with the present
invention. The lip, bottom wall, side walls, and other details of
the bucket are omitted to simplify the drawing.
[0032] FIG. 11 is a perspective view of an enclosure for a
monitoring system in accordance with the present invention.
[0033] FIG. 12 is a perspective view of a nozzle and/or wiping tool
for keeping a transparent wall clean in accordance with the present
invention.
[0034] FIG. 13 is a front perspective view of a device for keeping
a transparent material clean in accordance with the present
invention.
[0035] FIG. 14 is a perspective view of a wear member with a unique
feature and/or pattern along the length of the expected wear
profile of the wear member in accordance with the present
invention.
[0036] FIG. 15 is a partial side view taken along lines 15-15 of
the wear member shown in FIG. 14.
[0037] FIG. 16 is a perspective view of a base with a unique
feature and/or pattern in the top surface of the base so that the
unique feature and/or pattern can only be seen when the wear member
is not present in accordance with the present invention.
[0038] FIG. 17 is a front view of a Human Machine Interface (HMI)
to be used with a monitoring system in accordance with the present
invention.
[0039] FIG. 18 is a front view of a mobile HMI to be used with a
monitoring system in accordance with the present invention.
[0040] FIG. 19 is a side view of an electronic sensor to determine
the fill of a bucket in accordance with the present invention.
[0041] FIG. 20 is a side view of an electronic sensor to determine
the fill of a truck body in accordance with the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] The present invention pertains to a system for monitoring
the status, health, and performance of wear parts used on various
kinds of earth working equipment including, for example, excavating
equipment and ground conveying equipment. Excavating equipment is
intended as a general term to refer to any of a variety of
excavating machines used in mining, construction and other
activities, and which, for example, include dozers, loaders,
dragline machines, cable shovels, face shovels, and hydraulic
excavators. Excavating equipment also refers to the ground-engaging
components of these machines such as the bucket, blade, or the
cutter head. Ground conveying equipment is also intended as a
general term to refer to a variety of equipment that is used to
convey earthen material and which, for example, includes chutes and
mining truck beds or bodies. The present invention is suited for
monitoring the status, health and performance of wear parts used on
excavating equipment in the form of, for example, excavating
buckets, blades, lips, teeth, and shrouds. Additionally, certain
aspects of the present invention are also suited for monitoring the
status and health of a wear surface in the form of, for example,
runners and truck beds or bodies. For convenience of discussion,
the wear part monitoring process is discussed in terms of a
monitoring system that monitors a point on a mining excavator,
however, the monitoring process may be used with other wear parts
used with many kinds of earth working equipment.
[0043] Relative terms such as front, rear, top, bottom and the like
are used for convenience of discussion. The terms front or forward
are generally used to indicate the usual direction of travel of the
earthen material relative to the wear part during use (e.g., while
digging), and upper or top are generally used as a reference to the
surface over which the material passes when, for example, it is
gathered into the bucket. Nevertheless, it is recognized that in
the operation of various earth working machines the wear assemblies
may be oriented in various ways and move in all kinds of directions
during use.
[0044] A mining excavator 1 is equipped with a bucket 3 for
gathering earthen material while digging (FIG. 1). The bucket 3
includes a frame or shell 4 defining a cavity 16 for gathering
material during the digging operation (FIG. 2). Shell 4 may include
a top wall 6 having attachment supports 8 to attach the bucket 3 to
earthmoving equipment 1, a bottom wall 10 opposite the top wall 6,
a rear end with a back wall 12, and a pair of opposing sidewalls 14
each located between the top wall 6, the bottom wall 10, and the
back wall 12. The shell 4 may be constructed with walls having a
single plate or may be constructed with portions of the bucket
having double plates as is well known. Multiple configurations of
buckets are known and variations in bucket geometry exist, for
example, the bucket may not have a top wall as in a dragline
bucket, the rear wall may be hinged as in a dipper bucket, or a
portion of the side walls may be hinged as in a hydraulic face
shovel bucket. The specific geometry of the bucket is not intended
to be limiting as the present invention can be used with various
types of buckets and with various types of wear parts used on earth
working equipment. The bucket 3 has a lip 5 that extends forward of
the bottom wall 10 and is the digging edge of the bucket 3 (FIGS. 2
and 3). The digging edge is that portion of the equipment that
leads the contact with the ground. Tooth assemblies and shrouds are
often secured to the digging edge to protect the edge and break up
the ground ahead of the lip 5. Multiple tooth assemblies 7 and
shrouds 9, such as disclosed in US Patent Application Publication
US-2013/0174453 which is incorporated herein by reference, may be
attached to lip 5 of bucket 3 (FIGS. 2-5). The illustrated tooth 7
includes an adapter 11 welded to lip 5, an intermediate adapter 13
mounted on adapter 11, and a point (also called a tip) 15 mounted
on base 13. Point 15 includes a rearwardly-opening cavity to
receive nose 17 of base 13, and a front end 19 to penetrate the
ground (FIG. 5). Securement mechanisms or locks 21 are used to
secure wear member 15 to base 13, and base 13 to nose 23 (FIG. 5).
Other tooth arrangements are possible, for example, the tooth
assembly 7a may be defined with just an adapter 11a secured to the
lip and a point 15a (FIG. 6), such as disclosed in U.S. Pat. No.
7,882,649 which is incorporated herein by reference. One aspect of
the present invention pertains to monitoring the presence and/or
health of the wear member on a base. For ease of discussion the
application generally discusses monitoring the presence and/or
health of a wear member on a base secured to an excavating bucket.
However, the invention could be used to monitor the presence and/or
health of a wear member on a base on various types of earth working
equipment and may monitor a point on an adapter, a point on an
intermediate adapter, an intermediate adapter on an adapter, an
adapter, a nose of a cast lip, a shroud, a lip, a blade, a wear
runner, a truck liner, or other wear member of other kinds of earth
working equipment. During the life of the bucket or other
equipment, the wear member wears out and needs to be replaced a
number of times.
[0045] When a wear member reaches a minimum recommended wear
profile (i.e., the wear member is considered fully worn), the wear
member is replaced so that production does not decrease and the
base, upon which the wear member rests, does not experience
unnecessary wear. FIG. 7A and 7B illustrate the steps to a
monitoring system that monitors the status and health of wear
members on an excavating bucket. The process displays three
different wear member checks that are performed in parallel and the
results of the three checks results in a process outcome (e.g.,
wear member ok for continued operation, wear member is worn, and
wear member is missing). Variations in the process exist, for
example, it may be desirable to only monitor if the wear members
are present or to only monitor when the wear members are worn such
that they should be replaced. In another example, it may be
desirable to perform more than 3 different wear member checks or to
perform less than 3 wear member checks or to only utilize portions
of the process. In another example the process may be performed in
serial (i.e., perform first wear member check and proceed to next
wear member check if needed). It is also possible for the system to
estimate the remaining useful life of the wear part based on the
amount of the wear part remaining and the rate of wear to assist
the operator in determining when to replace the wear parts.
[0046] Because each type of wear member has a recommended or set
minimum wear profile, one of the wear member checks may be to
determine the current length of each wear member on the bucket. The
monitoring system 25 may use an electronic sensor 27 to determine
the current length of each wear member on the bucket (FIG. 8). The
length of the wear members may be, for example, determined by a
camera, an ultra-sonic sensor, a laser interferometer, or another
distance measuring sensor. In some embodiments the camera may be an
optical camera or the camera may be a thermal imaging camera. In
some embodiments, the monitoring system may be equipped with lights
to illuminate the wear part(s) being monitored so that the
electronic sensors may provide accurate readings. The lights
illuminating the wear part(s) may alternatively be a part of the
earth working equipment or it may not be necessary to illuminate
the wear parts. If the monitoring system uses a camera to determine
the lengths of the wear members on the bucket, the camera may first
acquire an image of the lip 5 and the attached tooth assemblies 7
(FIG. 3). Next programmable logic on a Central Processing Unit
(CPU), controller, PC, or Programmable Logic Controller (PLC) (all
of which will be generally referenced as a controller) may apply a
reference line to the image of the bucket lip (not shown). The
reference line may, for example, define the limit of wear allowed
for each of the wear members, may represent the lip of the bucket,
or the reference line may be an arbitrary line to establish a
"rearward edge" or end point for the programmable logic. The
reference line may be, for example, straight or non-straight
depending on the type of lip and/or wear members. The reference
line (not shown) will preferably be located rearward of the leading
edge of the lip 5 (FIG. 5). The programmable logic may have
integrated vision recognition software to determine the leading
edge of each wear member on the lip of the bucket. The vision
recognition software may be, for example, In-Sight sold by Cognex.
The programmable logic is programed to count the number of pixels
between the reference line and the leading edge of each wear
member. Based on the pixel count the programmable logic is
programmed to determine the current length of each wear member.
Once the current length of each wear member is determined, the
programmable logic compares the current length to the set minimum
wear profile for the type of wear members installed on the bucket.
The programmable logic may reference a database with the type of
wear members currently installed on the bucket or may determine the
type of wear members installed on the bucket using vision
recognition software. The programmable logic may also reference a
database of bucket and wear part geometry to assist the vision
recognition software in determining the type and number of wear
members installed on the bucket. If the length of each wear member
on the bucket is greater than the set minimum wear profile (i.e.
within a set range) and the results of the other parallel wear
member checks are acceptable (e.g., wear member is on the base and
the number of edges extending from the base match the expected
number of edges extending from the base) the programmable logic may
be programmed to loop back to the start of the process and again
determine the length of each wear member (FIGS. 7A and 7B). The
programmable logic may continually loop through the process or
there may be a delay built into the process so that the process is
run once during a set time limit. If the current length of at least
one wear member was close to the minimum wear profile (i.e. within
a set range) and the results of the other parallel wear member
checks are acceptable (e.g., wear member is on the base and the
number of edges extending from the base match the expected number
of edges extending from the base), the programmable logic may be
programed to produce a precautionary alert that a specific wear
member is close to needing replacement. The alert may be, for
example, a visual alert, haptic feedback, and/or an audio alert.
The monitoring system may wirelessly provide the alerts to
equipment operators and/or wireless devises for access by the
operator or other such as maintenance personnel, mine site managers
or the like. If, however, the length of each wear member is not
greater than the minimum wear profile (i.e. less than a set range)
and the results of the other parallel wear member checks are
acceptable (e.g., wear member is on the base and the number of
edges extending from the base match the expected number of edges
extending from the base) the programmable logic may be programed to
produce an alert that the wear member has been worn. The
programmable logic may be programmed to immediately produce the
alert or, to reduce false alarms; the programmable logic may be
programmed, for example, to repeat the process a preset number of
times or to repeat the process over apreset time frame to validate
that outcome of the process. This reduces the likelihood that the
programmable logic does not register an object obstructing the wear
member or the electronic sensor as a worn or missing wear
member.
[0047] Because each wear member and each base has a specific
geometry, another wear member check may be to determine the
features of each wear member and base on the bucket to assist with
knowing if the wear member is still attached to the base. As will
be disclosed in detail below, unique features and/or patterns may
also be included on the wear member or on the base to assist with
knowing if the wear member is still attached to the base. If the
key features, unique features and/or patterns are incorporated onto
the wear member and the monitoring system is able to detect the
feature and the results of the other parallel wear member checks
are acceptable (e.g., wear profile is acceptable and the number of
edges extending from the base match the expected number of edges
extending from the base), the monitoring system is programmed that
the wear member has not been lost from the excavating equipment. In
an alternative embodiment, the unique features and/or patterns are
incorporated onto a base such that the unique feature and/or
pattern can only be seen if the wear member is missing. If the
monitoring system registers the features and/or pattern and the
results of the other parallel wear member checks are not acceptable
(e.g., wear profile is not acceptable and the number of edges
extending from the base does not match the expected number of edges
extending from the base), the monitoring system is programmed to
produce an alert that the wear member has been lost.
[0048] Because each base has a specific number of edges extending
from it (i.e., for each base there is one wear part extending from
the base), another wear member check may be to determine how many
edges are extending from the base attached to the lip of the bucket
to assist with knowing if the wear member is still attached to the
base. This may be done by counting the number of edges extending
from the base or lip (i.e., the number of edges extending from the
base or lip in a forward direction parallel to the motion of the
bucket in a normal digging operation) and comparing them to the
expected number of edges extending from the base or lip. If, for
example, the number of edges extending from the base or lip does
not match the expected number of edges extending from the base or
lip and the results of the other parallel wear member checks are
acceptable (e.g., wear profile is acceptable and the wear part is
on the base), the programmable logic is programed to give a
precautionary alert (not shown) and/or may be programed to repeat
the monitoring process from the beginning. The monitoring process
may be repeated because there may have been an error in the process
(e.g., a rock or other item was miss-interpreted as a wear member).
In a similar fashion if the wear member is on the base but the
number of edges extending from the base does not match the expected
number of edges extending from the base and the wear profile of the
wear part is not acceptable, the programmable logic is programed to
repeat the monitoring process from the beginning (not shown in
FIGS. 7A and 7B). In an alternative embodiment the programmable
logic may be programed to send a precautionary alert (e.g., the
wear member may be worn but something may be lodged between the
wear members, or the wear member may be lost and an object is being
misinterpreted as a wear member). If the wear profile is acceptable
and the number of edges extending from the base matches the
expected number of edges extending from the base but the wear
member is not on the base (e.g. unique feature on base normally not
visible when wear member is present is currently visible), the
programmable logic may be programed to repeat the monitoring
process from the beginning as something may have caused an error in
the process (not shown in FIGS. 7A and 7B). If the wear profile is
not acceptable and wear member is not on the base but the number of
edges extending from the base matches the expected number of edges
extending from the base, the programmable logic may be programed to
repeat the monitoring process from the beginning as something may
have caused an error in the process (not shown in FIGS. 7A and 7B).
If the wear profile is acceptable but the number of edges extending
from the base does not match the expected number of edges extending
from the base and the wear member is not on the base, the
programmable logic may be programed to repeat the monitoring
process from the beginning as something may have caused an error in
the process (not shown in FIGS. 7A and 7B).
[0049] The results and alerts from the process may be sent to a
Human Machine Interface (HMI). Details of the HMI will be discussed
in further detail below. The bucket health monitoring system may
also communicate with other computer systems wirelessly or through
a cable the specific wear member(s) needing maintenance either
because the wear member is lost or because the wear member is worn
past the minimum wear profile. In addition the monitoring system
may store all of the results from the process.
[0050] In addition to monitoring the status and health of the wear
members on the bucket, the monitoring system may monitor the
performance of the bucket or other wear members. For example, the
monitoring system may determine how full the bucket is loaded
during the digging cycle. As the bucket is loaded, the material
being excavated has a tendency to fill the bucket with an
established profile. Once the bucket 3a has been filled by the
operator the electronic sensors 27 measure the distance D1 to the
load 91 within the bucket 3a (FIG. 19) and programmable logic uses
the distance and a database of established fill profiles to
determine the volume of the load within the bucket. The electronic
sensors 27 and programmable logic may also determine a percentage
that the bucket has been filled. The percentage may be determined
by comparing the current fill of the bucket to the rated capacity
of the bucket. In an alternative embodiment, the electronic sensors
27 may measure the distance D1 to the load 91 within a truck body
3b (FIG. 20) and programmable logic uses the distance and a
database of established fill profiles to determine the volume of
the load within the truck body. Similar to the bucket the
electronic sensors may be used to determine the percentage that the
truck body has been filled. The electronic sensor may be a camera,
a laser range finder, an ultrasonic sensor, or another distance
measuring sensor. Programmable logic may determine the percentage
the bucket is filled based on the distance to the load within the
bucket and. The results from the current digging cycle and past
digging cycles may be communicated to the equipment operator or to
other databases and computer systems. This allows the equipment
operator to adapt how the operator digs to optimally fill the
bucket and truck body. The monitoring system may, for example, use
the same electronic sensors used for monitoring the status and
health of the wear parts or may use separate electronic sensors to
monitor the fill of the bucket. The electronic sensors may be, for
example, a camera, a laser range finder, or an ultrasonic sensor.
The camera may be, for example, a 3D camera capable of determining
depth or may be a camera coupled with vision recognition software
as outlined above. It is also possible for the electronic sensors
for determining the fill of the bucket to be separate components
from the monitoring system and not be incorporated with the
monitoring system. The use of a monitoring system to monitor the
filling of a bucket could be used as a stand-alone system, i.e.,
without a system to monitor the presence and/or health of the wear
parts. This type of monitoring system could also be used in
non-bucket applications (e.g., such as truck trays) to monitor the
efficiency or optimization of the operator.
[0051] The monitoring system may be equipped with electronic
sensors that are capable of determining the cycle time of a digging
cycle. For example, the monitoring system may be equipped with an
accelerometer and an inclinometer (not shown). The inclinometer
provides the orientation of the bucket and the accelerometer
registers a spike in force when the bucket is at the appropriate
digging orientation and thus indicating that the digging cycle has
started. Programmable logic may determine the time from the start
of one digging cycle to the start of the second digging cycle
(i.e., time between peaks when inclinometer indicates that the
bucket is at the appropriate digging orientation). The results from
the current cycle time and past cycle times may be communicated to
the equipment operator or to a wireless device. This allows the
operator to adjust the digging operation for optimal performance.
It is also possible for the electronic sensors for determining the
cycle time to not be incorporated with the monitoring system.
Monitoring the fill of a bucket or truck tray and/or cycle time can
help mine operators (or the like) to better optimize its
operations. In an alternative embodiment, a pressure sensor may be
used instead of an accelerometer to determine when the digging
cycle has started. The pressure sensor may be a hydraulic pressure
sensor integrated with the boom of the earth working equipment. In
another preferred embodiment, a strain gauge or load cell is used
to determine when the digging cycle has started. The strain gauge
or load cell may be located in the bucket or a wear member on the
bucket. In an alternative embodiment, GPS may be used to determine
the orientation of the bucket.
[0052] The monitoring system may be equipped with electronic
sensors that are capable of determining high impact events on the
bucket digging edge (i.e., higher than experienced during normal
digging operation). For example, the monitoring system may utilize
an accelerometer, strain gauge, load cell, or pressure sensor to
determine peak impacts (not shown). Programmable logic may record
the time of the high impact event. The results of the high impact
events may be communicated to the equipment operator or to a
wireless device. It is also possible for the electronic sensors for
determining the high impact event to be separate components from
the electronic sensor for determining the digging cycle time or not
be incorporated with the monitoring system.
[0053] In accordance with one embodiment of the invention the
monitoring system 25 having at least one electronic sensor is
incorporated with the bucket 3 so that the sensor always has a
clear line of sight to the digging edge or lip 5 of the bucket 3
regardless of how the operator orients the bucket 3 during the
digging and dumping operation (FIGS. 9 and 10). The electronic
sensor may be, for example, integrated with the shell 4 of the
bucket (FIG. 10), integrated between two interior plates of a
bucket having a double wall shell (not shown), or installed on the
bridge 29 or top of the bucket (FIG. 9). The electronic sensors may
be, for example, a camera, an ultra-sonic sensor, or a laser
interferometer. The camera may be, for example, a Cognex 7100
camera. Nevertheless, the monitoring system could be mounted or
integrated with, for example, a boom or other support of the
excavating equipment, or to the body of the excavating equipment.
In a non-bucket application, the monitoring system may be
preferably mounted and or integrated to a base member supporting
the wear part. The base member may be, for example, a truck tray or
a blade. If the monitoring system is fixed to the truck tray the
monitoring system may monitor the presence and/or health of runners
on the truck tray. Similarly, if the monitoring system is fixed to
the blade of a dozer or grader the monitoring system may monitor
the presence and/or health of the end bits on the blade or the
leading edge of the blade. Like mounting the monitoring system on
the bucket, mounting on the truck tray or blade would provide a
clear line of sight to the part or parts being monitored.
[0054] The electronic sensor(s) 27 may be housed in one or more
enclosures 31 in one or more locations on the wear part that
engages and moves the ground to be excavated to protect the
electronic sensor(s) 27 from the harsh mining environment and to
keep the aperture 33 of the housing of the electronic sensor 27
free of fines, dirt, or other material that may negatively impact
the electronic sensor 27 (FIGS. 8 and 11). The enclosure 31 may
have one or more mounting brackets 35 for mounting the enclosure 31
on the first wear part. The enclosure 31 may house additional
electronic equipment (not shown) for controlling and processing the
data from the electronic sensor 27. In an alternative embodiment,
some or all of the additional electronic equipment may be housed on
the excavating equipment or in a remote location (not shown). For
example, one or more electronic sensors 27 may be located in one or
more locations in/on the bucket and the electronic sensors 27 may
communicate via a wire or wirelessly with other electronic sensors
and/or the additional electronic equipment within the cab of the
excavating equipment. In alternative embodiments, one or more
electronic sensors 27 (shown in phantom lines in FIG. 9) may be
located on or in a second wear part(s) that are attached to the
first wear part(s) that engages and moves the ground to be
excavated. The first wear part(s) may be, for example, a bucket, a
blade, a truck body, or the like and the second wear part(s) may
be, for example, a point, an intermediate adapter, an adapter, a
shroud, a nose, a lip, a wear runner, a truck liner, or the like.
The electronic sensor(s) in the second wear part may communicate
with electronic sensor(s) on the first wear part, the second wear
part(s) and/or with the additional electronic equipment that may be
located on the first wear part or located remote to the first wear
part. As with the electronic sensor(s) in the first wear part, the
electronic sensor(s) in the second wear part may communicate via a
wire or wirelessly. The additional electronic equipment may be, for
example, a controller, a power supply, a camera, and/or a wireless
device. The controller may be, for example, an S7-1200 PLC sold by
Siemens. The power supply may power just the electronic sensor or
may also power the additional electronic equipment. In an
alternative embodiment, two power supplies are provided. A first
power supply to power the electronic equipment and a second power
supply to power the additional electronic equipment. The power
supply may be, for example, a power supply sold by TDK-Lambda
and/or an SDC-5 Power Supply. The camera may be, for example, a
Closed-Circuit Television (CCTV) camera. The CCTV camera may
provide a HMI with a live feed of the lip of the bucket. Details of
the HMI will be discussed in further detail below. The wireless
device may be, for example a wireless serial device server sold by
B &B Electronics (formerly Quatech).
[0055] The enclosure may have at least one cutout 37 on one side so
that the aperture 33 of the at least one electronic sensor 27 has a
clear line of sight to the lip 5 of the bucket 3 (FIGS. 8, 9 and
11). In an alternative embodiment, the bucket may have a cutout 39
so that the aperture of the electronic sensor has a clear line of
sight to the lip (not shown) of the bucket (FIG. 10). The cutout 37
or 39 may be covered with a transparent wall 41, a translucent
wall, or a clear wall so that the electronic sensor is completely
sealed within the enclosure (FIGS. 8, 10, and 11). In addition a
nozzle 43 may be directed to spray air, water, or another type of
cleaning agent on the transparent wall 41 so that as dirt and fines
accumulate the air, water or cleaning agent cleans the transparent
wall 41 and keeps the transparent wall 41 see through (FIG. 12). In
an alternative embodiment, the electronic sensor may have a built
in transparent cover to protect the aperture of the electronic
sensor and the nozzle may be directed to spray the air, water, or
cleaning agent directly on the transparent cover of the electronic
sensor (not shown). In an alternative embodiment, a wiping tool 45
may be provided to clean off the transparent cover of the aperture
or the transparent wall 41 (FIG. 12). The wiping tool may be
integrated with a nozzle for spraying the air, the water, or the
cleaning agent. In an alternative embodiment the wiping tool may be
a separate tool from the nozzle. The wiping tool may be, for
example, a comb, brush, or a squeegee. In an alternative
embodiment, the cutout 37 in the enclosure or the cutout within the
bucket may be provided with a first spool 47 of transparent
material 49 that stretches across the cutout to a second spool 51
(FIG. 13). As the transparent material 49 becomes opaque, a motor
(not shown) may spin the second spool 51 so that the transparent
material 49 moves from the first spool 47 to the second spool 51
and a new section of transparent material 49 covers the cutout. In
an alternative embodiment, the cutout may be provided with multiple
layers of transparent material so that when the top layer needs to
be replaced the old top layer can be torn away to expose a new
layer of transparent material (not shown). In yet another
alternative embodiment, the aperture of the electronic sensor may
have a movable cover. The movable cover may cover the electronic
sensor when not in use and may be removed so that the electronic
sensor can take a measurement (not shown).
[0056] The electronic sensor 27 and additional electronic equipment
(not shown) may be mounted on vibration dampening devices 53 so
that the vibrations of the digging and dumping operation do not
negatively affect the electronic sensor 27 and additional
electronic equipment (FIG. 8). Various vibration dampening devices
53 known in the industry may be used to dampen the vibrations
experienced. The vibration dampening devices 53 may be, for
example, mounted to the top and bottom of a mounting unit 55 that
holds the electronic sensor 27. The vibration dampening devices 53
may be, for example, elastomers or springs.
[0057] A unique feature and/or pattern 57 may be added along the
length of the expected wear profile of the wear member 15 to aid
the monitoring system in determining the current wear profile of
the wear member 15 (FIGS. 14 and 15). The unique feature and/or
pattern 57 may be added to the wear member 15 at the time of
manufacture or after manufacturing. The unique feature and/or
pattern 57 may be, for example, grooves 59 and/or ridges cut, cast,
or forged into the top exterior surface 61 of the wear member 15.
In an alternative embodiment, the unique feature and/or pattern may
be a hardfacing material applied to the top exterior surface of the
wear member (not shown). As the wear member 15 penetrates the
ground and is worn the unique features and/or pattern 57 also wears
away. The electronic sensor may be able to detect how much of the
unique features and/or pattern 57 remains (e.g., how many grooves
59 and/or ridges remain). Based on the current wear profile and the
set minimum wear profile, the health monitoring unit can send an
alert (which could be a visual, audible, and/or haptic alarm) when
the wear member 15 is about to be worn to the minimum wear profile.
A separate alert may be sent when the wear member 15 has been worn
past the minimum wear profile.
[0058] Unique features and/or patterns may be incorporated onto the
wear member or base to aid in absence and presence detection. The
unique feature and/or pattern may be added to the wear member or
base at the time of manufacture or after manufacturing. The unique
feature and/or pattern 57 may be, for example, grooves 59 and/or
ridges cut, cast, or forged into the top exterior surface 61 of the
wear member (FIGS. 14 and 15). In an alternative embodiment, the
unique feature and/or pattern may be a hardfacing material applied
to the top exterior surface of the wear member (not shown). In an
alternative embodiment, the unique feature and/or pattern 63 may
be, for example, a shape cut, cast, or forged into the top surface
65 of the base 13 so that the unique feature and/or pattern 63 is
only visible if the wear member is no longer attached to the base
13 (FIGS. 9 and 16). In an alternative embodiment, hardfacing may
be used to apply a shape to the top surface of the base (not
shown). In an alternative embodiment, a shape 67 may be cut in the
top surface 65 of the base 13 and a medallion 69 may be press fit,
glued, or otherwise secured within the cut (FIG. 16).
[0059] At least one HMI 71 may be provided to display the current
status and health of the wear members on the bucket (FIGS. 17 and
18). The HMI 71 may be hard wired to the monitoring system or may
be a wireless device 81 (FIG. 18). The HMI 71 may be located in the
cab 2 of the excavating equipment 1 (FIG. 1) or may be located in a
remote location. In addition the HMI may be integrated with a
display system currently in the excavating equipment (e.g., with
the OEM display), may be integrated with a new display system
within the excavating equipment, or may be integrated with a remote
display system. The HMI 71 may be configured to provide a graphical
display 73 of the current status of the wear members on the lip of
the bucket (FIGS. 17 and 18). The HMI 71 may, for example, provide
visual alerts (e.g., text 75 and/or pictorial images), haptic
feedback (e.g., vibrations), and audio alerts regarding the status
of each wear member (FIG. 17). The visual alert may be, for
example, a graphical picture 77 displaying each wear member and the
status of each wear member (i.e., absent/present, acceptable wear,
needing maintenance). The HMI 71 may be designed to display a live
image 79 of the lip of the bucket so that an operator can visually
check that an alert is valid. The HMI may be designed to display a
history chart (not shown) so that an operator can determine when an
alert happened so that an operator can take the necessary actions
if a wear member is lost.
[0060] The various monitoring systems and features can be used
together or as a single stand-alone system without the other
capabilities. Although the above discussion has discussed the
invention in connection with teeth on a bucket, the system can be
used to sense the presence and/or health of other wear parts on a
bucket such as shrouds, wings, and/or runners. Moreover, systems of
the present invention can also be used to monitor the presence and
or health of wear parts on other kinds of earth working equipment
such as runners on chutes or truck trays, or end bits on
blades.
[0061] The above disclosure describes specific examples for a
bucket wear monitoring system. The system includes different
aspects or features of the invention. The features in one
embodiment can be used with features of another embodiment. The
examples given and the combination of features disclosed are not
intended to be limiting in the sense that they must be used
together.
* * * * *